Egg carton insert

ABSTRACT

An egg carton insert includes an N row by M column array of interconnected domes. Each dome is sized to enclose a top portion of an egg. Each dome is connected to each neighboring dome in the array. The array of domes forms an opening between each group of four adjacent domes. The array is arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed. The overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton.

TECHNICAL FIELD

The present disclosure relates to packaging. Example embodiments related to an insert for improved packaging of eggs in cartons.

BACKGROUND

An egg carton is a package designed for carrying and transporting whole eggs. Referring to FIG. 1, a typical carton 100 used at retail stores is illustrated. The carton 100 may include a bottom 110 comprising an array of dimples 112 connected to each other. The array of dimples 112 may be connected to a bottom rim 114 around the perimeter of the array. Each dimple 112 may be shaped to support the bottom of a single egg. One or more of the regions between any group of four dimples may be formed as a cone 116 that may extend above the plane of the bottom rim 114 to a height not substantially greater than the top of an egg expected to be carried in the carton 100. The cones 116 may inhibit, but do not prevent, an egg in the carton from contacting eggs in adjoining dimples 102.

The egg carton may include a top 120. The top 120 may be flexibly connected along a top back edge 128 to a bottom back edge 118 in a manner allowing the top 120 to be closed over the bottom 110. When the carton is closed, a top rim 124 may be substantially in contact with one or more portions of the bottom rim 114. Each cone 116 may extend no higher than an inside upper surface of the top 122.

The egg carton may include a flap 130 flexibly connected to a bottom front edge 119 for releasably securing the top 120 in place when the carton 100 is closed. The flap outer surface 136 may abut a top inside front surface 126 when the carton 100 is closed. The flap 130 may include detents 132 sized and shaped to mate with holes 129 formed in the top 120 to releasably secure the top 120 in place when the carton 100 is closed.

This egg carton 100 structure may protect eggs against stresses exerted during some forms of transportation and storage by absorbing shock. An egg carton 100 may be manufactured from various materials, including foamed plastics such as polystyrene foam, clear plastic, recycled paper, and molded pulp.

While a typical egg carton 100 is illustrated in FIG. 1, other variations are known. For example, the flap 130 may comprise three detents 132 for engaging three holes 120 in the top 120; the middle cone 116 may be replaced with a divider that extends across both columns of the array of dimples 112; and some portion of one or more cones 116 may extend through the top 120. A typical egg carton 100 can accommodate one dozen eggs—though egg cartons 100 for other amounts, such as four, six, eight, ten, eighteen (for example, comprising three columns of six eggs), are known.

Online grocers may allow consumers to order groceries and other products typically found in grocery stores, online. Either the grocer, or a third party, then may deliver the ordered goods to consumers. Often, a variety of mixed good, for example, eggs, bread, milk, and potato chips, are packaged in the same bag or box.

SUMMARY

In certain example embodiments described herein, an egg carton insert includes an N row by M column array of interconnected domes. Each dome is sized to enclose a top portion of an egg. Each dome is connected to each neighboring dome in the array. The array of domes forms an opening between each group of four adjacent domes. The array is arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed. The overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton.

In some embodiments, at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array. In some embodiments, the insert material is molded pulp.

In some embodiments, N is at least two and M is at least two. In such embodiments, in each even-numbered column, each odd-numbered dome position is vacant; and in each odd-numbered column, each even-numbered dome position is vacant.

In certain example embodiments described herein, a method for packing eggs includes providing an N row by M column egg carton containing a plurality of eggs. An egg carton insert is provided in the form of an N row by M column array of interconnected domes as described above. The array is placed over the eggs such that each dome aligns with a dimple. The egg carton is closed over the eggs and the egg carton insert.

In certain example embodiments described herein, an egg carton insert includes a substantially flat elongated rectangle of material. The material is characterized by a length less than the interior length of an egg carton, a width less than the interior width of the egg carton; and a thickness less than one half the height of an egg to be carried in the egg carton. The material defines therein an N row by M column array of through-holes of common diameter, the hole diameter less than the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton.

These and other aspects, objects, features, and advantages of the example embodiments will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of illustrated example embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a typical egg carton.

FIG. 2 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 3 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 4 illustrates an egg carton insert, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 5 is a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein.

FIG. 6 is a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

Turning now to the remaining drawings, in which like numerals indicate like (but not necessarily identical) elements throughout the figures, example embodiments are described in detail.

Overview

Delivering eggs purchased from an online retailer in cartons can result very high egg breakage rates, especially if the online retailer uses a common carrier for delivery. Egg breakage rates can increase if the egg carton is delivered in the same overall package, for example a cardboard box, along with heavy products or products packaged in hard-sided containers. A typical egg carton is not designed to withstand the forces likely to be encountered by the eggs being handled like books, clothing, and other goods delivered by common carriers. Even specialty carriers, accustomed to transporting fragile items, can see unacceptable breakage rates. Private testing has shown breakage rates as high as 44% for 6-count and 12-count egg cartons shipped for overnight delivery in outer boxes with other grocery products.

Embodiments of the technology disclosed herein include devices, systems, and methods for supplementing a typical egg carton with an insert that can reduce the rate of egg breakage during transport. Some embodiments disclosed herein have demonstrated breakage rates of less than 3%.

Example Architectures

Referring to FIG. 2, and continuing to refer to prior figures for context, a first embodiment of an egg carton insert 200 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert 200 is a six row 202 a-202 f by two column 204 a-204 b array of domes 210. While 6×2 is the most common egg carton 100 configuration, the egg carton insert 200 can be sized to any commonly-used N row×M column egg carton 100, such as 4×4, 6×3, etc.

Each dome 210 in FIG. 2 is shaped and sized to enclose a top portion of an egg. In some embodiments, the dome is shaped and sized to enclose less that the portion of an egg above its largest substantially round cross section. Other dome forms, including a truncated dome with a solid top, a truncated dome with an open top, and a pyramidal dome, can be used. In the example embodiment of FIG. 2, each dome 210 includes a substantially cruciform feature 240 that can facilitate orienting each egg top portion in its corresponding dome 210. Egg carton inserts 200 can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt.

Each dome 210 can be connected to each neighboring dome in the array. In the example embodiment of FIG. 2 representing a pulp insert, each dome 210 is connected to each neighboring dome 210 at the dome edge, including by a small bridge 220. In other embodiments, each dome 210 can be connected to neighboring domes 210 without the use of a bridge 220.

The array of domes 210 forms an opening 230 between each group of four adjacent domes 210. Each opening 230 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 230 can provide lateral stability to the combined egg carton 100 and egg carton insert 200. The loose, but laterally restrained, coupling between the egg carton insert 200 and the egg carton 100 can contribute to the protection of the eggs contained in the egg carton 100. The egg carton insert 200 is arranged such that each dome 210 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 200 can be placed.

The overall dimensions of the egg carton insert 200 are such that the egg carton 100 can be closed when the egg carton insert 200 is placed over each egg occupying a dimple 116 of the egg carton 100.

In some embodiments, at least one dome 210 defines therein a cutout 212 along a portion of the at least one dome at a long side of the array. The cutout 212 is oriented substantially parallel to the long side of the array. The cutout 212 can be in the shape of an arch, a rectangle, or other shape for providing clearance for egg carton 100 features that would otherwise impede closing the egg carton 100 over the egg carton insert 200 when the egg carton 100 dimples 112 are holding eggs.

Referring to FIG. 3, and continuing to refer to prior figures for context, a second embodiment of an egg carton insert 300 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. The illustrated egg carton insert 300 is a substantially flat 6×2 array of rings 310 defining holes therein. While 6×2 is the most common egg carton 100 configuration, the egg carton insert 300 can be sized to any commonly used N row×M column egg carton 100. The length of the egg carton insert 300 is less than the interior length of an egg carton 100. The width of the egg carton insert 300 is less than the interior width of an egg carton 100. The thickness of the egg carton insert 300 is less than one half the height of an egg to be carried in the egg carton 100. The overall dimensions of the egg carton insert 300 are such that the egg carton 100 can be closed when the egg carton insert 300 is placed over one egg occupying each dimple 166 of the egg carton 100.

Each ring 310 in FIG. 3 defines therein a hole 320 shaped and sized to fit over a top portion of an egg placed in an egg carton 100. In some embodiments, each ring 310 defines a hole 320 therein that is shaped and sized to encircle the egg above its largest substantially round cross section, leaving a portion of the egg projecting through the ring 310. While the outer portion of the ring 310 illustrated in FIG. 3 is substantially circular, other ring forms, including various regular polygons and truncated polygons, can be used. The hole 320 formed by each ring 310 is aligned with a corresponding dimple 116 of the egg carton 100.

Each ring 310 is connected to each neighboring ring 310 in the array. In the example embodiment of FIG. 3 representing a pulp insert, each ring 310 is connected to each neighboring ring 310 at the ring edge. Egg carton inserts 300 can be made from other materials, such as foamed plastics, rubber, clear plastic, and felt.

The array of rings 310 forms an opening 330 between each group of four adjacent rings 310. Each opening 330 can receive a cone 116 of the egg carton 100. Inserting a cone 116 into one or more of the openings 330 can provide lateral stability to the combined egg carton 100 and egg carton insert 200. The loose, but laterally restrained, coupling between the egg carton insert 300 and the egg carton 100 can contribute to the protection of the eggs from damage. The egg carton insert 300 is arranged such that each ring 310 corresponds to a dimple 112 of an egg carton 100 into which the egg carton insert 300 can be placed.

Referring to FIG. 4, and continuing to refer to prior figures for context, a third embodiment of an egg carton insert 400 is illustrated in perspective view, in accordance with example embodiments of the technology disclosed herein. In the egg carton insert 400 of FIG. 4, each odd-numbered ring position of the egg carton insert illustrated in FIG. 3 in the second column 420 each is vacant, and each even-numbered ring position of the egg carton insert illustrated in FIG. 3 in the first column 410 is vacant.

Example Processes

Referring to FIG. 5, a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block 510. For example, a 6×2 conventional egg carton 100 as shown in FIG. 1, with one egg in each carton dimple 116, is provided.

An N row by M column egg carton insert in the form of an array of interconnected domes is provided—Block 520. For example, the egg carton insert 200 in the form of a 6×2 array of domes 210 of FIG. 2 is provided. Each dome 210 is sized to enclose a top portion of an egg. Each dome 210 is connected to each neighboring dome 210 in the array 200. The array of domes 210 forming an opening 230 between each group of four adjacent domes 210. The array is arranged such that each dome 210 corresponds to a dimple 116 of the egg carton 100. The overall dimensions of the egg carton insert 200 are such that the egg carton 100 can be closed when the egg carton insert 200 is placed over one egg occupying each dimple 116 of the egg carton.

The array is placed over the eggs such that each dome 210 aligns with a dimple 116—Block 530. For example, the edges of the array can be aligned with the bottom rim 112 of the open egg carton 100. Even an imperfect alignment, up to one half an egg diameter off, between the egg carton insert 200 and the carton 100 containing eggs will create a self alignment. The egg carton, containing the eggs and the egg carton insert 200, is closed—Block 540. For example, closing the top 120 and locking the top by aligning detents 132 with holes 139 will further facilitate the self-alignment.

Referring to FIG. 6, a block flow diagram depicting a method to pack eggs, in accordance with certain example embodiments of the technology disclosed herein, is shown. In such methods an N row by M column egg carton containing a plurality of eggs is provided—Block 610. For example, a 6×2 conventional egg carton 100 as shown in FIG. 1, with one egg in each carton dimple 116, is provided.

An egg carton insert in the form of a substantially flat elongated rectangle of material is provided—Block 620. For example, the egg carton insert 300 having a length less than the interior length of the egg carton 100, a width less than the interior width of the egg carton 100, and a thickness less than one half the height of an egg in the egg carton 100 is provided. The material defines therein an N row by M column array of through-holes of common diameter. The hole diameter less then the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton.

The material is placed over the eggs such that each hole aligns with a dimple 116—Block 630. The egg carton, containing the eggs and the egg carton insert 300, is closed—Block 640.

The example systems, methods, and acts described in the embodiments presented previously are illustrative, and, in alternative embodiments, certain acts can be performed in a different order, in parallel with one another, omitted entirely, and/or combined between different example embodiments, and/or certain additional acts can be performed, without departing from the scope and spirit of various embodiments. Accordingly, such alternative embodiments are included in the technology described herein.

Although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Modifications of, and equivalent components or acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the present disclosure, without departing from the spirit and scope of embodiments defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures. 

1. An egg carton insert, comprising: an N row by M column array of interconnected domes: each dome sized to enclose a top portion of an egg; each dome connected to each neighboring dome in the array; the array of domes forming an opening between each group of four adjacent domes; and the array arranged such that each dome corresponds to a dimple of an egg carton into which the insert can be placed; wherein the overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton.
 2. The egg carton insert of claim 1, wherein at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array; wherein the cutout corresponds to a feature a bottom rim of the egg carton.
 3. The egg carton insert of claim 1, wherein the insert material is molded pulp.
 4. The egg carton insert of claim 1, wherein: N is at least two and M is at least two; in each even-numbered column, each odd-numbered dome position is vacant; and in each odd-numbered column, each even-numbered dome position is vacant.
 5. A method for packing eggs, comprising: providing an N row by M column egg carton containing a plurality of eggs; providing an egg carton insert in the form of an N row by M column array of interconnected domes: each dome sized to enclose a top portion of an egg, each dome connected to each neighboring dome in the array, the array of domes forming an opening between each group of four adjacent domes, and the array arranged such that each dome corresponds to a dimple of the egg carton, wherein the overall dimensions of the egg carton insert are such that the egg carton can be closed when the insert is placed over one egg occupying each dimple of the egg carton; placing the array over the eggs such that each dome aligns with a dimple; and closing the egg carton.
 6. The method of claim 5, wherein at least one dome defines therein a cutout along a portion of the at least one dome at a long side of the array.
 7. The method of claim 5, wherein the insert material is molded pulp.
 8. The method of claim 5, wherein N is at least two and M is at least two; in each even-numbered column, each odd-numbered dome position is vacant; and in each odd-numbered column, each even-numbered dome position is vacant.
 9. An egg carton insert, comprising: a substantially flat elongated rectangle of material characterized by: length less than the interior length of an egg carton; width less than the interior width of the egg carton; and thickness less than one half the height of an egg to be carried in the egg carton; wherein the material defines therein an N row by M column array of through-holes of common diameter, the hole diameter less then the diameter of an egg, and each hole aligned with a corresponding dimple of the egg carton; and wherein the material defines therein an opening between each group of four adjacent holes, each opening corresponding to a cone of the egg carton.
 10. The egg carton insert of claim 9, wherein insert material is molded pulp.
 11. The egg carton of claim 9, wherein N is at least two and M is at least two; in each even-numbered column each odd-numbered array position is vacant; and in each odd-numbered column, each even-numbered array position is vacant. 12-14. (canceled) 